Surgical stapling device with compressible staple cartridge

ABSTRACT

A surgical instrument includes a tool assembly having an anvil and a cartridge assembly that are movable in relation to each other between an open position and a clamped position to clamp tissue between the anvil and the cartridge assembly. The staple cartridge and/or the anvil includes a tissue contact surface that is formed of or includes a compliant material to allow the tool assembly to adapt to the topography of the tissue being clamped to uniformly compress the tissue along the length of the tool assembly and minimize trauma inflicted on the tissue.

FIELD

This disclosure is directed to surgical devices for stapling tissue and, more particularly, to surgical stapling devices including a tool assembly having structure to evenly compress tissue.

BACKGROUND

Known surgical stapling devices include a tool assembly having an anvil and a cartridge assembly that have tissue contacting surfaces. The anvil and the cartridge assembly are coupled to each other and are movable in relation to each other between spaced and clamped positions. The anvil and the cartridge assembly each include a tissue contact surface. When the tool assembly is moved from an open position to a clamped position, the tissue contact surfaces of the anvil and the staple cartridge define a uniform tissue gap in which tissue is received and clamped.

The tissue contact surfaces of the anvil and the staple cartridge are typically formed from rigid materials. When tissue is clamped between the tissue contact surfaces of the anvil and the staple cartridge, trauma can be inflicted on the tissue. Where the tissue has a density that is not uniform along the length of the tool assembly, which is common in diseased or irradiated tissue, the degree of compression of the tissue can vary along the length of the tool assembly resulting in increased trauma to thicker and/or denser tissue.

A continuing need exists in the stapling arts for a tool assembly that can evenly compress tissue along the length of the tool assembly to minimize the infliction of trauma on the tissue.

SUMMARY

Aspects of the disclosure are directed to a surgical stapling device that includes a tool assembly having a cartridge assembly and an anvil that are movable in relation to each other between open and clamped positions. The cartridge assembly includes a staple cartridge. Each of the staple cartridge of the cartridge assembly and the anvil includes a tissue engaging surface. One or both of the tissue engaging surfaces of the anvil and the staple cartridge includes or is formed with a compliant material that allows the tool assembly to adapt to the topography of the tissue being clamped between the tissue engaging surfaces to uniformly compress the tissue along the length of the tool assembly.

One aspect of this disclosure is directed to a tool assembly for a surgical stapling device. The tool assembly tool assembly includes an anvil and a cartridge assembly. The anvil has a first tissue engaging surface. The cartridge assembly includes a cartridge channel and a staple cartridge. The staple cartridge includes a body having a second tissue engaging surface. The body is received within the cartridge channel. The second tissue engaging surface is formed of a compliant material. The compliant material defines openings to facilitate passage of staples through the compliant material.

Other aspects of the disclosure are directed to a surgical stapling device including a handle assembly, an elongate body, and a tool assembly. The elongate body has a proximal portion coupled to the handle assembly and a distal portion. The tool assembly is supported on the distal portion of the elongate body and includes an anvil and a cartridge assembly. The anvil has a first tissue engaging surface. The cartridge assembly includes a cartridge channel and a staple cartridge. The staple cartridge includes a body having a second tissue engaging surface. The body is received within the cartridge channel. The second tissue engaging surface is formed of a compliant material that defines openings to facilitate passage of staples through the compliant material.

In aspects of the disclosure, the compliant material is formed integrally with the body of the staple cartridge.

In some aspects of the disclosure, the compliant material is secured to the body of the staple cartridge.

In certain aspects of the disclosure, the compliant material is secured to the body of the staple cartridge by painting.

In aspects of the disclosure, the compliant material is secured to the body of the staple cartridge by evaporation.

In some aspects of the disclosure, the compliant material is secured to the body of the staple cartridge by over-molding.

In certain aspects of the disclosure, the compliant material is selected from the group consisting of memory foam, polyurethane, hydrogels, gelatins, polysaccharides and rubber.

In aspects of the disclosure, the compliant material has a thickness to allow the second tissue engaging surface of the staple cartridge to adapt to the localized topography and thickness of the tissue “T”.

In some aspects of the disclosure, the thickness of the compliant material is from about 0.100 inches to about 1.5 inches.

In certain aspects of the disclosure, the first tissue engaging surface of the anvil is formed from a compliant material.

Other features of the disclosure will be appreciated from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the disclosed surgical stapling device are described herein below with reference to the drawings, wherein:

FIG. 1 is a side perspective view of a surgical stapling device according to aspects of the disclosure with a tool assembly in an open position;

FIG. 2 is an enlarged view of the indicated area of detail shown in FIG. 1;

FIG. 3 is a cross-sectional view taken along section lines 3-3 of FIG. 2;

FIG. 4 is a cross-sectional view of the tool assembly shown in FIG. 3 with the tool assembly in a clamped position;

FIG. 5 is a side cross-sectional view of another version of the tool assembly of the surgical stapling device shown in FIG. 1 with the tool assembly in the open position; and

FIG. 6 is a side cross-sectional view of the tool assembly shown in FIG. 5 with the tool assembly in the clamped position.

DETAILED DESCRIPTION

The disclosed surgical stapling device will now be described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. However, it is to be understood that the aspects of the disclosure described herein are merely exemplary of the disclosure and may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the disclosure in unnecessary detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the disclosure in virtually any appropriately detailed structure.

In this description, the term “proximal” is used generally to refer to that portion of the device that is closer to a clinician, while the term “distal” is used generally to refer to that portion of the device that is farther from the clinician. In addition, the term “endoscopic” is used generally to refer to endoscopic, laparoscopic, arthroscopic, and/or any other procedure conducted through small diameter incision or cannula. Further, the term “clinician” is used generally to refer to medical personnel including doctors, nurses, and support personnel.

A surgical instrument is disclosed that includes a tool assembly having an anvil and a cartridge assembly that are movable in relation to each other between an open position and a clamped position to clamp tissue between the anvil and the cartridge assembly. In aspects of the disclosure, the staple cartridge and/or the anvil includes a tissue contact surface that is formed of or includes a compliant material to allow the tool assembly to adapt to the topography of the tissue being clamped to uniformly compress the tissue along the length of the tool assembly.

FIG. 1 is a perspective view of a surgical stapling device including aspects of the disclosure shown generally as stapling device 10. The stapling device 10 includes a handle assembly 12, an elongate body or adapter assembly 14, and a tool assembly 16. The elongate body 14 defines a longitudinal axis “X” and includes a proximal portion 14 a supported on the handle assembly 12 and a distal portion 14 b that supports the tool assembly 16. In some aspects of the disclosure, the tool assembly 16 forms part of a reload assembly 18 that includes a proximal body portion 18 a that is adapted to be releasably coupled to the distal portion 14 b of the elongate body 14 of the stapling device 10. The proximal body portion 18 a of the reload assembly 18 includes a distal portion that supports the tool assembly 16. In alternate aspects of the disclosure, the tool assembly 16 is secured to the distal portion 14 b of the elongate body 14.

The handle assembly 12 of the stapling device 10 includes a body 20 defining a stationary handle 20 a, actuation buttons 22, and a rotation knob 23. The actuation buttons 22 can be depressed to actuate the tool assembly 16, e.g., approximate the tool assembly 16, articulate the tool assembly 16, fire staples, etc. . . . . The rotation knob 23 is rotatably supported on the body 20 of the handle assembly 12 and supports the elongate body 14 of the stapling device 10 such that rotation of the rotation knob 23 causes rotation of the elongate body 14 and the tool assembly 16 in relation to the handle assembly 12. In aspects of the disclosure, batteries (not shown) are supported in the stationary handle 20 a to power the handle assembly 12. U.S. Pat. No. 10,123,799 discloses a powered handle assembly and adapter assembly suitable for use with the tool assembly 16.

It is envisioned that the stapling device 10 need not be powered but can also include a manually powered handle assembly such as described in U.S. Pat. No. 5,865,361 (“the '361 patent”). It is also envisioned that the stapling device 10 can be adapted to be supported on a robotic surgical system and need not include a handle assembly.

FIGS. 2-4 illustrate the tool assembly 16 which includes an anvil 24 and a cartridge assembly 26 that are coupled together at their proximal ends such that the tool assembly 16 can move between an open position (FIG. 1) and a clamped position (FIG. 4). The anvil 24 includes a tissue engaging surface 24 a that defines a plurality of staple forming pockets 25 (FIG. 3). The cartridge assembly 26 includes a staple cartridge 28 and a cartridge channel 30 that receives the staple cartridge 28. The staple cartridge 28 includes a tissue engaging surface 48 (FIG. 2). In the open position, a distal end portion of 50 of the anvil 24 is spaced from a distal end portion 52 of the staple cartridge 28 to facilitate passage of tissue “T” between the anvil 24 and the cartridge assembly 26 to a position between the tissue contacting surfaces 24 a and 48 of the anvil 24 and the staple cartridge 28. In the clamped position, the tissue engaging surface 24 a of the anvil 24 is in juxtaposed alignment with the tissue engaging surface 48 of the staple cartridge 28.

In some aspects of the disclosure, the staple cartridge 28 can be removed from the cartridge channel 30 and replaced to facilitate reuse of the stapling device 10. Alternately, the staple cartridge 28 can be fixedly retained within the cartridge channel 30 and the reload assembly 18 (FIG. 1) can be replaced to facilitate reuse of the stapling device 10.

The staple cartridge 28 includes a body 54 that defines a central knife slot 56 (FIG. 2) and staple receiving pockets 58 (FIG. 2) that are positioned on each side of the central knife slot 56. Each of the staple receiving pockets 58 receives a staple 59. In aspects of the disclosure, the staple receiving pockets 58 are aligned in rows on each side of the central knife slot 56. Although three rows of staple receiving pockets 58 are illustrated in FIG. 2, it is envisioned that one or more rows of staple receiving pockets 58 can be formed on each side of the central knife slot 56.

The tissue engaging surface 48 of the staple cartridge 28 is formed from or includes a compliant material 60 that can deform inwardly in response to movement of the tool assembly 16 from the open position to the clamped position. In aspects of the disclosure, the compliant material 60 is integrally formed with the body 54 of the staple cartridge 28. In other aspects of the disclosure, the compliant material 60 is secured to the body 54 of the staple cartridge. As the tool assembly 16 is moved from the open position to the clamped position, the force of the tissue “T” on the tissue engaging surface 48 of the staple cartridge 28 generated by movement of the anvil 24 in the direction of arrows “A” in FIG. 4 towards the cartridge assembly 26 deforms the tissue engaging surface 48 of the staple cartridge 28 inwardly towards the cartridge channel 30. This inward deformation of the tissue engaging surface 48 of the staple cartridge 28 may not be uniform along the length of the staple cartridge 28 and will depend on the thickness and density of the tissue “T” being clamped on respective portions of the staple cartridge 28. For example, in areas of the tissue engaging surface 48 where the tissue “T” is thicker and/or more dense, the tissue engaging surface 48 of the staple cartridge 28 will undergo a greater degree of deformation than in areas of the tissue engaging surface where the tissue “T” is thinner and/or less dense.

In aspects of the disclosure, and as illustrated in FIG. 4, the body 54 of the staple cartridge 28 or portions thereof can be formed of a compliant material 60 that deforms inwardly when tissue “T” is compressed between the anvil 24 and the cartridge assembly 26 as described above. Alternately, as shown in FIGS. 5 and 6, the compliant material 60 forming the tissue engaging surface 48 of the staple cartridge 28 can be formed on or applied to the staple cartridge 28 using a variety of different fastening techniques or methods. For example, the compliant material can be secured to the body 54 of the staple cartridge 28 using fasteners or clips, applied to or grown on the body 54 by “painting” or by applying layers of compliant material 60 using evaporation. Alternately, the compliant material 60 could be secured to the body 54 of the staple cartridge with an adhesive or by an over-molding process.

FIGS. 5 and 6 illustrate the tool assembly 16′ of the stapling device 10 (FIG. 1) tool assembly 16′ is moved from its open position to its clamped position. As shown, prior to clamping tissue “T” (FIG. 5), the distance between the tissue engaging surface 24 a, which is defined by the compliant material 60, and an outer surface 24 b of the anvil is “X”, and the distance between the tissue engaging surface 48 of the staple cartridge 28 and an outer surface 30 a of the cartridge channel 30 is “Y”. Upon clamping of the tissue “T” (FIG. 6), the compliant material 60 compresses such that the distance “X” is reduced to “X1” and the distance “Y” is reduced to “Y1”, wherein “X” is greater than “X1” and “Y” is greater than “Y1”.

In aspects of the disclosure, the compliant material 60 can be formed from a variety of different materials such as memory foams including polyurethanes and other viscoelastic materials, hydrogels such as collagen, gelatin, and polysaccharides, rubbers, or the like. The thickness of the compliant material will depend upon the material selected but should be sufficiently thick to allow the tissue engaging surface 48 of the staple cartridge 28 to adapt to the localized topography and thickness of the tissue “T” being compressed to provide substantially uniform compression along the length of the tool assembly 16. In aspects of the disclosure, the thickness of the compliant material is from about 0.100 inches to about 1.5 inches.

It is envisioned, as illustrated in FIGS. 5 and 6, that the compliant material 60 can also be secured to the anvil 24 such that the tissue engaging surface 24 a of the anvil 24 is also compliant. In this regard, the compliant material 60 would function as described above regarding the tissue engaging surface 48 of the staple cartridge 28.

Although this disclosure is directed to a linear endoscopic stapler, it is envisioned that the disclosed aspects of the tool assembly 16 could also be incorporated into open type stapling, circular stapling devices, curved stapling devices, circular stapling devices and any other device in which tissue is clamped between two jaws to be treated, e.g., vessel sealing devices suturing devices or the like.

It is noted that the compliant surfaces of the anvil 24 (FIG. 5) and the staple cartridge 28 (FIGS. 3 and 5), unlike buttress materials, define openings 70 that facilitate passage of the staples 59 such that after the stapling process is completed remain secured to the anvil 24 and/or the staple cartridge 28.

Persons skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary aspects of the disclosure. It is envisioned that the elements and features illustrated or described in connection with one exemplary aspect of the disclosure may be combined with the elements and features of another without departing from the scope of the disclosure. As well, one skilled in the art will appreciate further features and advantages of the disclosure based on the above-described aspects of the disclosure. Accordingly, the disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims. 

What is claimed is:
 1. A tool assembly for a surgical stapling device, the tool assembly comprising: an anvil having a first tissue engaging surface; and a cartridge assembly including a cartridge channel and a staple cartridge, the staple cartridge including a body having a second tissue engaging surface, the body being received within the cartridge channel, the second tissue engaging surface being formed of a compliant material, the compliant material defining openings to facilitate passage of staples through the compliant material.
 2. The tool assembly of claim 1, wherein the compliant material is formed integrally with the body of the staple cartridge.
 3. The tool assembly of claim 1, wherein the compliant material is secured to the body of the staple cartridge.
 4. The tool assembly of claim 3, wherein the compliant material is secured to the body of the staple cartridge by painting.
 5. The tool assembly of claim 3, wherein the compliant material is secured to the body of the staple cartridge by evaporation.
 6. The tool assembly of claim 3, wherein the compliant material is secured to the body of the staple cartridge by over-molding.
 7. The tool assembly of claim 1, wherein the compliant material is selected from the group consisting of memory foam, polyurethane, hydrogels, gelatins, polysaccharides and rubber.
 8. The tool assembly of claim 1, wherein the compliant material has a thickness to allow the second tissue engaging surface of the staple cartridge to adapt to the localized topography and thickness of the tissue “T”.
 9. The tool assembly of claim 8, where the thickness of the compliant material is from about 0.100 inches to about 1.5 inches.
 10. The tool assembly of claim 1, wherein the first tissue engaging surface of the anvil is formed from a compliant material.
 11. A surgical stapling device comprising: a handle assembly; an elongate body having a proximal portion coupled to the handle assembly, and a distal portion; and a tool assembly supported on the distal portion of the elongate body, the tool assembly including: an anvil having a first tissue engaging surface; and a cartridge assembly including a cartridge channel and a staple cartridge, the staple cartridge including a body having a second tissue engaging surface, the body being received within the cartridge channel, the second tissue engaging surface being formed of a compliant material, the compliant material defining openings to facilitate passage of staples through the compliant material.
 12. The surgical stapling device of claim 11, wherein the compliant material is formed integrally with the body of the staple cartridge.
 13. The surgical stapling device of claim 11, wherein the compliant material is secured to the body of the staple cartridge.
 14. The surgical stapling device of claim 13, wherein the compliant material is secured to the body of the staple cartridge by painting.
 15. The surgical stapling device of claim 13, wherein the compliant material is secured to the body of the staple cartridge by evaporation.
 16. The surgical stapling device of claim 13, wherein the compliant material is secured to the body of the staple cartridge by over-molding.
 17. The surgical stapling device of claim 11, wherein the compliant material is selected from the group consisting of memory foam, polyurethane, hydrogels, gelatins, polysaccharides and rubber.
 18. The surgical stapling device of claim 11, wherein the compliant material has a thickness to allow the second tissue engaging surface of the staple cartridge to adapt to the localized topography and thickness of the tissue “T”.
 19. The surgical stapling device of claim 18, where the thickness of the compliant material is from about 0.100 inches to about 1.5 inches.
 20. The surgical stapling device of claim 11, wherein the first tissue engaging surface of the anvil is formed from a compliant material. 